Modular sortation units, systems, and methods

ABSTRACT

A modular transfer system with a primary flow system and a diverter system that is repositionable along a track system. The primary flow system includes a primary flow belt for conveying an article along a primary flow path from an infeed side of the modular transfer system to a pass-through side of the modular transfer system. The diverter system that is repositionable along the track system between the infeed side and the pass-through side by attachment within one or more channels.

CROSS REFERENCE

This application claims the priority benefit under at least 35 U.S.C. §119 of U.S. Patent Application No. 62/590,233 filed Nov. 22, 2017, theentirety of which is hereby incorporated by reference.

BACKGROUND Field

The present disclosure relates to systems and methods for conveyinggoods from a first location to a second location. More specifically,some aspects of the present disclosure relate to modular conveyorcomponents that can transfer goods to other components of a conveyorsystem.

Description of Certain Related Art

Conveyors can be used in various commercial and manufacturingapplications to transport articles between different processing stationsand locations. A conveyor typically includes a conveyor belt or chainthat is arranged in an endless loop and driven to transport the articleson the belt or chain surface along a generally horizontal path.

SUMMARY OF CERTAIN FEATURES

This disclosure encompasses various embodiments of a modular transferunit and related methods. In some embodiments, the modular transfer unitcan include a main belt and a diverter system that can be repositionedrelative to the main belt. In certain embodiments, the diverter systemcan be mounted on and slidable relative to a track system. In certainembodiments, the diverter system can be repositioned along the tracksystem without removing the diverter system therefrom. These embodimentscan provide the advantages of making the modular transfer unit easilycustomizable and reconfigurable.

In another aspect of certain embodiments, the modular transfer unit caninclude one or more filler sheets. The filler sheets can fill or spangaps between diverter systems or ends of the modular transfer unit. Incertain embodiments, the filler sheets engage lower portions of movablemembers on the main belt. The filler sheets can provide an increasedspeed for articles travelling on the main belt and engaged with upperportions of the movable members. In certain implementations, the fillersheets can be coated in a sound absorbing material. The sound absorbingfiller can reduce noise created by operation of the modular sortingsystem.

In another aspect of certain embodiments, the modular transfer unit caninclude a control system. The control system can automatically operatethe modular transfer unit in response to reconfiguration of the divertersystem on the track system. In one embodiment, the control system canautomatically detect the reconfiguration of the diverter system. Inanother embodiment, the control system can prompt a user to inputupdated parameters that reflect the reconfiguration of the divertersystem. The control system can provide the advantages of being easilyreconfigurable in the field and with minimal user training and minimalor no programming support.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages are described belowwith reference to the drawings, which are intended to illustratenon-limiting example embodiments of modular transfer units.

FIG. 1 is a top down schematic of an embodiment of a modular transferunit.

FIG. 2A is a partial cross-sectional schematic of the modular transferunit of FIG. 1.

FIG. 2B is another partial cross-sectional schematic of the modulartransfer unit of FIG. 1.

FIG. 3 is a perspective view of an embodiment of a modular transferunit.

FIG. 4 is a top down schematic view of the modular transfer unit.

FIG. 5 is a top down schematic view of the modular transfer unit havinga main belt removed for clarity.

FIG. 6 is a cross-section of the modular transfer unit at a divertersystem.

FIG. 7 is a cross-section of the modular transfer unit at a fillersheet.

FIG. 8 shows the modular transfer unit having a control system.

FIG. 9 shows a reconfiguration of the modular transfer unit.

FIG. 10 is a top down schematic of another modular transfer unit.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

Various modular transfer units are disclosed. The modular transfer unitscan be utilized in a conveyor system which can have other conveyingdevices, such as belted conveyors and/or roller conveyors, which canconvey articles as well as receptacles which can receive the conveyedarticles at desired locations. The modular transfer units may beself-contained devices which beneficially allow the modular transferunit to be selectively used in or removed from a conveyor system, ormoved around a conveyor system on an as-needed basis. The modulartransfer units may be stand-alone devices (e.g., self-supporting and/ornot physically secured to other components of the conveyor system). Themodular transfer units described herein can have a rectangular shapewith four sides. This geometry may allow the modular transfer unit to bemore widely implemented in current commercial conveyor systems. However,it is to be understood that the modular transfer unit can have differentshapes with a different number of sides (e.g., pentagon with five sides,hexagon with six sides, circular, etc.).

The modular transfer units described herein can receive articles fromother components of a conveyor system. In some embodiments, the modulartransfer unit can allow the article to “pass through” the modulartransfer unit such that the article is allowed to continue along its“primary flow path”. That is, the modular transfer unit conveys thearticle to a component of the conveyor system which is positionedopposite of the component from which the modular transfer unit receivedthe article. This may occur with little to no change in direction forthe article.

In some embodiments, the modular transfer unit can divert the articlefrom this “primary flow path”. That is, the modular transfer unitredirects the article to a component of the conveyor system which is notpositioned opposite of the component from which the modular transferunit received the article. This may occur with a significant change indirection for the article. For example, as will be shown in theembodiments below, this may cause a generally perpendicular (e.g., about90 degree) shift in direction for the article; however, it is to beunderstood that lower degrees of shift (e.g., less than or equal toabout: 30 degrees, 45 degrees, 60 degrees, 75 degrees, 90 degrees, etc.)are contemplated.

For purposes of this disclosure, the modular transfer units will bedescribed as having a single infeed side, a single pass-through side,and one or more divert sides. This would be applicable in circumstancesin which the modular transfer unit is utilized in a conveyor systemwhich provides articles to the modular transfer unit at a singlelocation. However, it is to be understood that the modular transfer unitcan be utilized in conveyor systems having other configurations andwhich may provide articles to the modular transfer unit at multiplelocations. In such circumstances, the modular transfer unit can havemultiple infeed sides. Moreover, the pass-through sides may be a divertside or vice versa (depending on the specific location at which themodular transfer unit receives an article).

While the present description sets forth specific details of variousembodiments, it will be appreciated that the description is illustrativeonly and should not be construed in any way as limiting. Additionally,although particular embodiments may be disclosed or shown in the contextof conveyor systems which convey articles, it is to be understood thatthe systems described herein can be utilized with any other types ofitems, goods or articles. As such, the terms articles, packages,articles, goods, and items may be used interchangeably. For example, anycomponent, structure, step, method, or material that is illustratedand/or described in one embodiments can be omitted or can be used withor instead of any component, structure, step, method, or material thisis illustrated and/or described in another embodiment.

Overview of a Modular Transfer Unit

With reference to FIGS. 1 and 2, a schematic of a modular transfer unit100 is illustrated. With reference first to FIG. 1, the modular transferunit 100 can have an infeed side 102 at which the modular transfer unit100 can receive one or more articles from a conveyor system. In someimplementations, the modular transfer unit 100 can be attached tocomponents of a conveyor system which deliver the articles to the infeedside 102 of the modular transfer unit 100. The modular transfer unit 100can allow articles to pass through the modular transfer unit 100 in aprimary flow path (e.g., in a direction along the x-axis). The modulartransfer unit 100 can have a pass-through side 104 at which the modulartransfer unit 100 can discharge articles which are intended to be passedthrough the modular transfer unit 100. In some implementations, themodular transfer unit 100 can be attached to components of a conveyorsystem which receive the articles discharged from the pass-through side104.

The modular transfer unit 100 can redirect or divert articles from theprimary flow path. The modular transfer unit 100 can have a first divertside 106 and/or a second divert side 108 at which the modular transferunit 100 can discharge articles which are intended to be diverted by themodular transfer unit 100. In some implementations, the first divertside 106 and/or the second divert side 108 of the modular transfer unit100 can be attached to components of a conveyor system which receive thearticles which have been diverted from the primary flow path of theconveyor system.

The modular transfer unit 100 can include a first conveyance system 110.The first conveyance system 110, which can be a primary flow system, canmove articles along a direction of the primary flow path (e.g., in adirection along the x-axis). As shown, the primary flow system 110 caninclude a primary flow belt 112 (also called a main belt). The primaryflow belt 112 can extend between the infeed side 102 and thepass-through side 104 of the modular transfer unit 100. The primary flowsystem 110 can include a driver 114, such as a motor, which can bedirectly coupled to the primary flow belt 112 or indirectly coupled viaone or more intermediate components, such as gears. The driver 114 canmove the primary flow belt 112 in a direction from the infeed side 102to the pass-through side 104 of the modular transfer unit 100. In someembodiments, the driver 114 can move the primary flow belt 112 in adirection from the pass-through side 104 to the infeed side 102 of themodular transfer unit 100. The driver 114 can be reversible orintermediate components between the driver 114 and the primary flow belt112 can allow the driver 114 to drive the primary flow belt 112 inreverse (e.g., a transmission with one or more gears).

In some embodiments, the primary flow belt 112 can be a roller-top belt,such as the 2253RT belt (available from System Plast S.r.l.). Theprimary flow belt 112 can include any feature or combination of featuresthat are the same, or similar to, those described in any of U.S. Pat.No. 7,021,454, issued Apr. 4, 2006, U.S. Patent Application PublicationNo. 2018/0257872, filed Mar. 8, 2018, and U.S. Patent ApplicationPublication No. 2018/0257110, filed Mar. 8, 2018, each of which areincorporated by reference herein in their entirety. In some embodiments,the primary flow belt 112 can have a length, measured from the infeedside 102 to the pass-through side 104 of between about 30″ to about250″. The primary flow belt 112 can have a width, measured in theconveying plane and generally orthogonal to the length, of between about16″ to about 34″. The driver 114 can be coupled to the primary flow belt112 via a roller, lagged roller, sprocket or other torque transmissionfeature. The primary flow belt 112 can comprise a plurality ofinterconnected modules, such as plastic belt modules comprising a bodyand one or more movable components. Modules that are adjacent to eachother in the conveying direction can be hingedly connected, such as witha hinge pin.

With continued reference to FIG. 1, the modular transfer unit 100 caninclude one or more additional conveyance systems such as a divertersystem 120 a. The diverter system 120 a can move articles in a directionwhich is non-parallel to the primary flow path of the conveyor system.For example, the diverter system 120 a can move articles in a directionnot parallel to the x-axis. As shown in the illustrated embodiment, thediverter system 120 a can move articles in a direction which isgenerally orthogonal to the primary flow path of the conveyor system(e.g., the diverter system 120 can move articles in a direction alongthe y-axis) or in another direction.

The diverter system 120 a can include a diverter belt 122 a. Thediverter belt 122 a can extend from the first divert side 106 and/or thesecond divert side 108 of the modular transfer unit 100. The diverterbelt 122 a can overlap at least partially with the primary flow belt112. The diverter system 120 a can include a driver 124 a, such as amotor, which can be directly coupled to the diverter belt 122 a orindirectly coupled via one or more intermediate components, such as atransmission. The driver 124 a can move the diverter belt 122 a in adirection between the second divert side 108 and the first divert side106 of the modular transfer unit 100. The driver 124 a can be reversibleor intermediate components between the driver 124 a and the diverterbelt 122 a can allow the driver 124 a to drive the diverter belt 122 ain reverse.

In some embodiments, the diverter belt 122 a comprises a non-modularbelt, such as a fabric conveyor belt. In certain embodiments, thediverter belt 122 a can be a Habasit NSW-5ELAV. In some variants, thediverter belt 122 a comprises a plurality of interconnected modules,such as plastic belt modules. Modules that are adjacent each other inthe conveying direction can be hingedly connected, such as with a hingepin. The driver 124 a can be coupled to the diverter belt 122 a via aroller. In some implementations, the roller can be a 1.9″ diameterroller.

The modular transfer unit 100 can include one or more filler sheets 120b. The filler sheets 120 b can partially or substantially completelyspan one or more gaps beneath the primary flow belt 112 in the modulartransfer unit 100. A gap can be located anywhere along the primary flowbelt 112 where the belt 112 is unsupported by the driver 114 or thediverter system 120. The filler sheet 120 b can engage with lowerportions of the movable components. The filler sheets 120 b can besubstantially stationary. For example, in some implementations, thefiller sheets 120 b are substantially stationary relative to thesurrounding environment, the diverter system 120 a, and/or a frame thatsupports the filler sheets and 120 b and/or the primary flow belt 112.In various embodiments, the filler sheets 120 b are not driven and/or donot contact the conveyed articles. In some implementations, the fillersheet 120 b can include a bonded friction coating on a top side.

In certain embodiments, the filler sheet 120 b can comprise (e.g., becoated with) a sound absorbing material. Such a filler sheet 120 b canreduce noise created by operation of the modular sorting system. In someimplementations, the sound absorbing material comprises a fabric, afiber-reinforced plastic, a rubber, or otherwise. In certain variants,the filler sheets 120 b comprise a generally rigid layer (e.g., metal orwood or plastic, such as steel or plywood or acrylic) and a soundabsorbing layer that comprises the sound absorbing material. The soundabsorbing layer can be on the top and/or bottom of the generally rigidlayer. In some embodiments, the sound absorbing layer is sufficientlytough and/or resilient to withstand substantially constant engagementwith primary flow belt 112.

With continued reference to FIG. 1, the modular transfer unit 100 caninclude a frame 130 that can be used to support one or more componentsof the modular transfer unit 100. The frame 130 can support componentsof the primary flow system 110 and the diverter system 120 a, and thefiller sheet 120 b. The modular transfer unit 100 can be a standalone,self-contained system capable of operating separately from a conveyorsystem. The frame 130 can be coupled with a conveyor system. In someimplementations, the frame 130 can be sized to fit between components ofa conveyor system. This can beneficially allow the modular transfer unit100 to be implemented on an as-needed basis in a conveyor system. Indoing so, the modular transfer unit 100 can be swapped from one positionin a conveyor system to another position in the conveyor systemdepending on the needs of the operator. In some implementations, theframe 130 can be sized to be retrofitted to existing conveyor systems.The frame 130 can be assembled together of shorter frame components orframe modules.

The frame 130 can include a track system. The track system can includefirst and second tracks, 131, 132. The first and second tracks 131, 132can be disposed on opposite sides of the frame 130. The first track 131can be generally aligned on the first divert side 106. The second track132 can be generally aligned along the second divert side 108. Thetracks 131, 132 can extend between the in-feed side 102 and thepass-through side 104 of the modular transfer unit 100. The tracks 131,132 can each be formed of a unitary structure. In other implementations,the tracks 131, 132 can be modular and assembled together of shorterlength track modules.

The tracks 131, 132 can include one or more channels. The channels canextend lengthwise (between the in-feed side 102 and the pass-throughside 104) on the frame 130. The tracks 131, 132 can be formed by anextrusion process to form therein the channels. The channels can extendsubstantially the length of the tracks 131, 132. In one implementation,the first and second tracks 131, 132 can comprise extruded aluminum.

The diverter system 120 a and/or the filler sheet 120 b can be mountedwith the channels in the first and second tracks 131, 132. The divertersystem 120 a and/or the filler sheet 120 b can be slidable along thechannels or fixed with the channels to reconfigure the modular transferunit 100. The diverter system 120 a and/or the filler sheet 120 b can beattached with the channels by one or more bolts, clamps, couplers, orother mechanical coupler.

The diverter system 120 a and/or the filler sheet 120 b can berepositionable along the tracks. The channels can enable the divertersystem 120 a and/or the filler sheet 120 b to be mountable at variouspositions between the in-feed side 102 and the pass-through side 104.This can have the advantage of making the modular transfer unit 100customizable by a user. An advantage of the modular transfer unit 100 isthe ability to easily move the diverter system 120 a and/or the fillersheet 120 b in the field. When issues occur during the design phase andin the field, the modular construction of the modular transfer unit 100makes quick work of being able to adapt the system according to usagerequirements. In several embodiments, the diverter system 120 a and/orthe filler sheet 120 b can be repositioned while remaining connected tothe frame 130. For example, in some embodiments, the diverter system 120a and/or the filler sheet 120 b can be repositioned along the trackswhile remaining connected to the tracks (e.g., not physically separatedfrom, or not disconnected and then reconnected).

The driver 114 and/or the primary flow belt 112 can be mounted to thetracks 131, 132. The tracks 131, 132 can be mounted or installed on theframe 130. The frame 130 can provide rigidity and support to the tracks131, 132 and the primary flow belt 112.

With reference next to FIG. 2A, a schematic of the primary flow belt 112and the diverter belt 122 a of the modular transfer unit 100 isillustrated. As shown, the primary flow belt 112 can be positioned abovethe diverter belt 122 a. Movable components 116 of the primary flow belt112 can contact the diverter belt 122 a. The movable components 116 canhave one or more translational and/or rotational degrees of freedom. Forexample, the movable components 116 can be in the form of balls whichprovide three rotational degrees of freedom. As another example, themovable components 116 can be in the form of rollers which provide onedegree of rotational freedom.

The movable components 116 can move in response to movement of theprimary flow belt 112 and/or the diverter belt 122 a. As shown in theillustrated embodiment, the movable components 116 can rotate about thex-axis (represented by arrow 118) in response to translation of thediverter belt 122 a in a direction along the y-axis (represented byarrow 126). An article (not shown) positioned on the primary flow belt112 and contacting the movable components 116 could thereby translate ina direction along the y-axis. This can allow the diverter belt 122 a toredirect or divert articles in a direction which is generally orthogonalto the primary flow path. In several embodiments, when the movablecomponents 116 pass over the diverter belt 122 a, the movable components116 are in continuous contact with the diverter belt 122 a. In someimplementations, the diverter belt 122 a is vertically fixed relative tothe primary flow belt 112. For example, in some embodiments, thediverter belt 122 a as a whole does not move up and down and/or into andout of engagement with the movable components 116. In some embodiments,the diverter belt 122 a is maintained in constant contact with and/or iscontinuously engaged with (e.g., abutted against) at least one of themovable components 116, such as the protruding lower portion of at leastone spherical ball. In certain embodiments, the primary flow belt 112does not include one or more motors that rotate the movable components116 relative to other of the movable components 116 and/or a base of theprimary flow belt in which the movable components 116 are journaled.

FIG. 2B is a section taken at 90 degrees relative to the section of FIG.2A. The primary flow belt 112 can be positioned above the filler sheet120 b and/or the diverter belt 122 a. The primary flow belt 112 can moveat a main belt speed relative to the filler sheet 120 b and/or thediverter belt 122 a. Lower portions of the movable components 116 of theprimary flow belt 112 can contact the filler sheet 120 b and/or thediverter belt 122 a. The movable components 116 can move in response tomovement of the primary flow belt 112 over the filler sheet 120 b. Asshown in the illustrated embodiment, the movable components 116 canrotate about the y-axis (represented by arrow 119) in response tointeraction with the filler sheet 120 b and/or the diverter belt 122 a.An article (not shown) positioned on the primary flow belt 112 andcontacting the movable components 116 could thereby translate in adirection along the x-axis or along the primary flow direction. Anarticle (not shown) positioned on the primary flow belt 112 andcontacting the movable components 116 could thereby translate in adirection along the primary flow direction relative to the primary flowbelt 112. The article can translate at a conveyance speed. Theconveyance speed can be double that of the main belt speed.

In some embodiments, the filler sheets 120 b assist in maintaining asubstantially constant conveyance speed of the conveyed article. Asdiscussed above, when the movable components 116 are in contact with thediverter belt 122 a, the article can be conveyed at a speed that isgreater than the speed of the primary flow belt 112 due to theadditional velocity provided by the rotation of the movable components116. However, when the movable components 116 are not in contact withthe diverter belt 122 a, the conveyed speed in such a region of theprimary flow belt 112 can drop to that of the speed of the primary flowbelt 112. This change in conveyance speed may be undesirable, such asbecause it may result in unintended movement of the article relative tothe belt 112, reduced ability to track the location of the article,and/or increased difficulty in handing the article. In some embodiments,the filler sheets 120 b can substantially or completely fill a gap, suchas between a first diverter belt 122 a and a second diverter belt 122 a,thereby maintaining the rotation of the movable components 116. This canresult in the conveyance speed of the article remaining substantiallyconstant. In various embodiments of the modular transfer unit 100, theconveyed speed of the article is substantially constant along the lengthof the modular transfer unit 100. In some variants of the modulartransfer unit 100, the conveyed article on the primary flow belt 112does not experience a sudden change in speed as an article passes intoor out of a region in which the movable components 116 are in contactwith the diverter belt 122 a. In several embodiments of the modulartransfer unit 100, the movable components 116 on the article conveyingside (e.g., the top side, not the return side) of the primary belt 112remain in motion (e.g., rotation) throughout the length of the modulartransfer unit 100. In some implementations, a substantially constantspeed indicates a maximum change in speed of approximately 10%. Thefiller sheet 120 b can comprise a unitary sheet, or a plurality ofindividual sheets that together form the filler sheet 120 b.

While the modular transfer unit 100 was described as having a singleinfeed side 102, a single pass-through side 104, and two divert sides106, 108, it is to be understood that fewer or greater number of sidesmay be used (e.g., five or more sides). Moreover, it is to be understoodthat the modular transfer unit 100 can include two infeed sides and twodischarge/divert sides. For example, the modular transfer unit 100 mayreceive articles at sides 102, 106. Articles received at side 102 may bedischarged at side 104 or diverted to side 108. Articles received atside 106 may be discharged at side 108 or diverted to side 104. Themodular aspect of the modular transfer unit 100 can beneficially allowthe modular transfer unit 100 to be implemented in a wide variety ofconveyance systems.

With reference next to FIG. 3, an embodiment of a modular transfer unit200 is illustrated. The modular transfer unit 200 can includecomponents, features, and/or functionality which are the same or similarto those of other modular transfer units described herein, such asmodular transfer unit 100 described above. The modular transfer unit 200can include a primary flow belt 212. The primary flow belt 212 cancomprise a modular conveyor belt, such as a belt made ofhingedly-connected belt modules (e.g., links). The primary flow belt 212can include multiple movable components 216 in the form of sphericalballs. The primary flow belt 212 can be operated via one or moredrivers, such as motorized rollers (not shown). Components of themodular transfer unit 200 can be supported by a frame 230. This canallow the modular transfer unit 200 to be swapped in and out of aconveyor system on an as-needed basis.

Example of a Modular Transfer Unit

FIG. 4 shows a modular transfer unit 300. Similar to the modulartransfer units 100 and 200, the modular transfer unit 300 can include aninfeed side 302 and a pass-through side 304. A main belt 312 (shown inpartial cut-away) can extend from the infeed side 302 to thepass-through side 304. The main belt 312 can include a plurality ofhingedly-connected belt modules. The belt modules can together form aloop. The loop can have an article conveying side and a return side. Thebelt modules can include a body. A plurality of the movable components116 can be rotatably mounted within the body. An upper portion of themovable components 116 can protrude above an upper surface of the bodyand a lower portion can protrude below a lower surface of the body.

A driver 314 can be mounted on the infeed side 302, the pass-throughside 304 or elsewhere on the main belt 312. A second driver 314 a can bemounted opposite the driver 314. The driver 314 can be coupled with amotor 315. The coupling with the motor 315 can include a transmissionfor transmitting a torque of the motor to the driver 314. The main belt312 can be looped over the drivers 314, 314 a. Application of a torqueto the driver 314 can rotate the driver 314 and thereby translate themain belt 312 in a primary flow direction from the infeed side 302towards the pass-through side 314. The drivers 314, 314 a can besprockets, rollers, lagged rollers, or other engagement members. Themotor 315 can be included with a gearbox or transmission.

At or adjacent to the infeed side 302, the modular transfer unit 300 caninclude an infeed detection zone 350. The infeed detection zone 350 canbe associated with an article sensor 360. At or adjacent to thepass-through side 304, the modular transfer unit 300 can include apass-through detection zone 358. The pass-through detection zone 358 canbe associated with an article sensor 368.

At different points along the main belt 312 between the infeed andpass-through sides 302, 304, the modular transfer unit 300 can includeone or more divert zones. The modular transfer unit 300 includes first,second, and third divert zones 352, 354, 356, although a greater orlesser number may be included in the modular transfer unit 300. Thedivert zones 352, 354, 356 can be aligned with one or more divertersystems, as discussed further below.

The divert zones 352, 354, 356 can be associated with one or morearticle sensors. The article sensors can include sensors 362, 364, and366. The article sensors can be one-dimensional (e.g., linear) acrossthe primary flow belt 312. The article sensors can define or align witha leading edge of the divert zones 352, 354, 356 and/or the detectionzones 350, 358. In some embodiments, the article sensors can be aphoto-eye. However, it is to be understood that other types of sensorscan be utilized, such as optical sensors, electromagnetic sensors,weight sensors, and other types of sensors. Moreover, although thedetection zones of the illustrated embodiment are linear in the plane ofthe primary flow belt 312, it is to be understood that the detectionzones can be two-dimensional in the plane of the primary flow belt 312and/or three-dimensional.

The divert zones 352, 354, 356 can be aligned with one or more divertchutes. The divert chutes can include first, second, and third chutes342, 344, 346. As shown, the first, second, and third divert zones 352,354, 356 align with first, second, and third chutes 342, 344, 346,respectively. The divert chutes 342, 344, 346 can be other conveyorunits, other modular transfer units, roller take-away units,catch-baskets, or other components of a conveyor system. Althoughillustrated on only one side of the main belt 312, the divert chutes342, 344, 346 can be aligned on either side thereof.

The chutes 342, 344, 346 can be associated with one or more articlesensors. The article sensors can include sensors 363, 365, and 367. Thearticle sensors can be one-dimensional (e.g., linear) across the chutes342, 344, 346, or multi-dimensional. In some embodiments, the articlesensors can be formed by a photo-eye. However, it is to be understoodthat other types of sensors can be utilized, such as optical sensors,electromagnetic sensors, weight sensors, and other types of sensors.

In some embodiments, information pertaining to the detection and divertzones can be relayed to a control system of the modular transfer unit300 and/or a control system of other components of the conveyor systemto which the modular transfer unit 300 is attached. This can allow thecontrol system to control the operation of the modular transfer unit 300based on the status of the articles on the modular transfer unit 300.The article sensors can provide an indication that the modular transferunit 300 has received an article at the infeed side 302 of the modulartransfer unit 300. The article sensors can provide an indication thatthe modular transfer unit 300 has discharged an article through thepass-through detection zone 358. The article sensors can sense arrivalof an article at the divert zones or at the chutes.

In some embodiments, the modular transfer unit 300 can include anon-board controller to which information pertaining to the detection anddivert zones can be relayed. This can allow the modular transfer unit300 to further operate as a stand-alone unit. In some implementations,the on-board controller can be connected to the conveyor system to whichthe modular transfer unit 300 is attached. This can allow the modulartransfer unit 300 to receive instructions from the conveyor system aboutspecific articles being conveyed. Such instructions may include whetherto allow the article to pass through the modular transfer unit 300 or tobe diverted from the primary flow path of the conveyor system.

The modular transfer unit 300 can include a frame 330. The frame 330 cancomprise one or more structural support components of modular transferunit 300. The frame 330 can be comprised of steel, aluminum, or otherrigid materials. The frame 330 can be modular. The frame 330 can includeone or more smaller (e.g., shorter) structural support components orstandardized modules that are assembled together to form the full lengthof the frame 330. Accordingly, the length of the frame 330 can becustomizable depending on usage requirements.

The frame 330 can provide structural support to the drivers 314, 314 ato support the main belt 312. The drivers 314, 314 a, and/or motor 315can be coupled with one or more mounting locations on the frame 330. Inone implementation, the drivers 314, 314 a can be journaled within theframe 330. The article sensors can be mounted on the frame 330. Theframe 330 can provide mounting locations to connect the modular transferunit 300 with the chutes and/or other adjacent components of a conveyorsystem, such as at the infeed and/or pass-through sides 302, 304.

The frame 330 can include a track system. The track system can includefirst and second tracks 331, 332. The first and second tracks 331, 332can be made of steel, aluminum, or other materials. The first and secondtracks 331, 332 can extend along opposite sides of the main belt 312.The drivers 314, 314 a, and/or motor 315 can be mounted on the tracks331, 332.

The frame 330 can make the modular transfer unit 300 a standalone,self-contained system capable of operating separately from a conveyorsystem. In some implementations, the frame 330 can be sized to fitbetween components of a conveyor system. This can beneficially allow themodular transfer unit 300 to be implemented on an as-needed basis in aconveyor system. In doing so, the modular transfer unit 300 can beswapped from one position in a conveyor system to another position inthe conveyor system depending on the needs of the operator. In someimplementations, the frame 330 can be sized to be retrofitted toexisting conveyor systems.

The modular transfer unit 300, shown without the main belt 312 in FIG.5, can include one or more of diverter systems. The diverter systems caninclude diverter systems 322, 324, 326. The diverter systems 322, 324,326 can correspond to the divert zones 352, 354, 356, respectively. Thediverter systems 322, 324, 326 can operate like the diverter system 120a and include the same components. The diverter systems 322, 324, 326can each include a divert belt, drivers, motors, and mounting bracketsor similar structure. The divert belt can contact the lower portion ofthe movable components 116 of the main belt 312. The diverter systems322, 324, 326 can be aligned generally perpendicularly with the primaryflow direction of the main belt 312, or at any other angle. The angle ofdivert from the diverter station can be determined by a ratio of themain belt speed to the diverter belt speed. By operating the divert beltof a diverter system, the movable components 116 can be rotated, asdescribed above with respect to FIG. 2A. The operation of the divertbelt can carry the article passing on the main belt 312 through one ofthe divert zones 352, 354, 356 towards one of the first or second divertsides 306, 308. The operation of the divert belt can carry the articleoff the main belt 312 and into the chute corresponding with the divertzone.

The modular transfer unit 300 can be configurable. The divert zonesand/or the detection zones can be positioned along the frame 330 betweenthe infeed and pass-through ends 302, 304. Accordingly, the positions ofthe diverter systems and/or chutes can be adjustable depending on use.

FIG. 6 is a cross-section of the modular transfer unit 300 through adiverter system. The modular transfer unit 300 can include the frame330. The frame 330 can include multiple structural components that areassembled together to provide a rigid platform for the tracks 331, 332.The frame 330 can include support rails. The support rails can includefirst and second support rails 390 a, 390 b. The first support rail 390a can be aligned on opposite sides of the modular transfer unit 300. Thesupport rails 390 a, 390 b can have a structurally rigid cross-sectionalshape. In some implementations, the support rails 390 a, 390 b can havean I-beam or C-beam shape. The support rails 390 a, 390 b can be made ofa rigid material such as steel, aluminum, or other suitable metals ornon-metallic materials.

The support rails 390 a, 390 b can include one or more caps 392. Thecaps 392 can be attachable by one or more mechanical couplers oradhesives. The caps 392 can enclose interior portions of the supportrails 390 a, 390 b. The interior portions can include access to theattachment locations for the tracks 331, 332, J-bolts 393, and/orrollers, or other catenary supports 614.

A strut or multiple struts 396 can connect the support rails 390 a, 390b. Multiple struts 396 can located between the in-feed end 302 and thepass-through end 304 of the unit 300. In one embodiment, the strut 396can be attached to the first and second rails 390 a, 390 b by J-boltassemblies. The J-bolt 394 can attach at one end within an aperture ofthe strut 396. An opposite end of the J-bolt 394 can attach with one ofthe support rails 390 a, 390 b. The opposite attachment end of theJ-bolt 394 can include a threaded section that can be inserted throughan aperture in the support rail. A nut or other mechanical attachmentcan be attached with the J-bolt such at the threaded end. The strut 396can provide support and rigidity to the other components of the modulartransfer unit 300.

The main belt 312 can be looped over the drivers 314, 314 a with anupper portion located on top of the modular transfer unit 300. A lowerportion of the main belt 312 can be routed below or interior to thesupport rails 390 a, 390 b. In one implementation, the modular transferunit 300 includes one or more rollers or catenary supports 614. Therollers or other support structures 614, such as but not limited to aflat support panel, ribs or other structure, can provide support toprevent sagging of the main belt 312 as it returns around the drivers314, 314 a. The rollers or catenary supports 614 can be attached betweenthe support rails and provide support the lower portion of the main belt312. A shaft of the roller 614 can be journaled within the support rails390 a, 390 b.

The support rails 390 a, 390 b can include a track mount 391. The trackmount 391 can provide an attachment location for attaching the tracks331, 332 with the support rails 390 a, 390 b. The track mount 391 caninclude one or more apertures for receiving bolts or other suitablemechanical couplers.

The track 331 can include a lower portion 335 a and an upper portion 337a. The track 332 can have the same structural components as the track331. The lower portion 335 a can be attachable with one of the supportrails 390 a, 390 b. The lower portion 335 a can be attachable with thetrack mount 391 on an upper end of the support rail 390 a. The lowerportion 335 a can include one or more channels or apertures. Thechannels or apertures can be sized to receive one or more bolts orscrews or other mechanical couplers for attaching at the track mount391.

The lower portion 335 a can include one or more T-shaped channels. TheT-shaped channels can be sized to receive a head of a support element,such as a bolt. The head can be slidable within the channel along thelength of the track 331. A threaded end of the bolt can protrude fromthe T-shaped channel. The threaded end of the bolt can be receivedwithin one or more apertures of the upper track mount 391. Nuts can beattached over the threaded end of the bolt to attach the track 331 andthe support rail 390 a. The bolt can be loosened and/or removed and evenwith the head of the bolt remaining within the T-shaped channel and theside track 331 can be alternately moved or fixed relative to the supportrail 390 a thereby.

The upper portion 337 a of the track 331 can include one or moreapertures or channels. The apertures or channels can include one or moremounting locations for attaching components with the modular transfersystem 300. The upper portion 337 a can attach with one or more spurs,chutes, or takeaways of a conveyor system. The apertures or channels caninclude one or more T-shaped slots for receiving the head of one or morebolts. The upper portion 337 a can attach with the motor 315, thechutes, or any of the article sensors. The sensor 362 is shown attachedwith the upper portion 337 a of the rail 332 by one or more mechanicalfasteners. The sensor 362 can include a light emitter 362 a and areflecting surface 362 b opposed on the tracks 331, 332. The upperportion 337 a can include one or more belt or chain guides 338.

An inner portion of the track 331 can include an attachment channel 334a. The attachment channel 334 a can be oriented upwardly, inwardly, orat an angle to a horizontal. The attachment channel 334 a can extend thelength of the track 331 or less than the length thereof. The attachmentchannel 334 a can be T-shaped and configured to secure a head of a bolt.The attachment channel 334 a can provide an attachment location for anyor all of the diverter systems. Like the track 331, the track 332 caninclude a lower portion 335 b, an upper portion 337 b, and/or anattachment channel 334 b.

The diverter system 322 can include one or more rollers 324 a, 324 b anda diverter belt 323. The diverter system 322 can include a motorassembly (not shown) for powering and providing torque to the drivers324 a, 324 b for rotating and moving the diverter belt 323. The rollersand belt can be disposed underneath the main belt 312. An upper surfaceof the diverter belt 323 belt can be in contact with the main belt 312.The upper surface of the diverter belt can contact lower surfaces of therotational members 116.

The diverter system 322 can include one or more brackets 326 a, 326 b.The brackets 326 can attach the drivers 324 a, 324 b and/or the motorwith the tracks 331, 332. The bracket 326 a can attach between theattachment channel 334 a and the roller 324 a. The head of a bolt can beinserted within channel 334 a and attached with the bracket 326 a at athreaded protruding end of the bolt. The diverter system 322 canalternately be slidable or fixed within the T-shaped channel 334 a byloosening or tightening the bolt. The channels 334 a can enable movementof the diverter system 322 longitudinally along the tracks 331, 332.

The above describes one possible implementation of a modular assemblyfor the diverter systems to be assembled and positionable within tracksof the modular transfer system 300. Other attachment arrangementsbetween the tracks 331 and the diverter systems are within the skill ofone of ordinary skill in the art of the present disclosure. The modulardesign can allow for additional diverter systems or other conveyancestations to be moved, added, or removed from the modular transfer unit300. This results in limited investment of time to reconfigure themodular transfer unit and minimal downtime.

The modular transfer unit 300 can include one or more filler sheets, asshown in FIG. 5. The filler sheets can include filler sheets 372, 374,376, 378. The filler sheets 372, 374, 376, 378 can be placed in one ormore gaps between the drivers 314, 314 a, and/or between the divertersystems 322, 324, 326. The filler sheets 372, 374, 376, 378 can be metalor wood. The filler sheets 372, 374, 376, 378 can include an uppersurface that is generally planer or otherwise shaped to engage themovable components 116. The filler sheets 372, 374, 376, 378 can extendacross the width of the modular transfer unit (e.g., between the tracks331, 332). The filler sheets 372, 374, 376, 378 can extend lengthwise(e.g., in the primary flow direction) to substantially fill the gaps. Agap can be considered substantially filled where no linear lengthgreater than a length between rows of movable components 116 in thelengthwise direction is left unfilled. In some implementations, theentire interior length of the modular transfer unit 300 between thedriver 314 and driver 314 a can be substantially filled with fillersheets 372, 374, 376, 378 or diverter systems 322, 324, 326.

The filler sheets 372, 374, 376, 378 can contact the lower portions ofthe movable components 116. Contact between the filler sheets 372, 374,376, 378 and the lower portions can cause the upper portions of themovable components 116 to spin in a direction of the primary flow pathof the main belt 312. Articles can travel on the main belt 312 at a mainbelt speed. Articles also engaged with the movable components 116 can bepropelled at conveyance speed in the primary flow direction at a speedgreater than the speed of the main belt 312. In some implementations,the engagement of the filler sheets 372, 374, 376, 378 with the movablecomponents doubles the conveyance speed relative to the main belt speed.Engagement of the diverter systems 322, 324, 326 with the lower portionsof the movable components 116 can have the same effect on the conveyancespeed as moving over the filler sheets. Accordingly, by filling theinterior length of the modular transfer unit 300 between the driver 314and driver 314 a with filler sheets 372, 374, 376, 378 or divertersystems 322, 324, 326, the speed of the articles on the main belt can beincreased (e.g., doubled) across the entire modular transfer unit 300.

The filler sheets 372, 374, 376, 378 can increase the processing ratesof the modular transfer unit relative to conveyances without fillersheets 372, 374, 376, 378. The modular transfer unit 300 can achieverates of between 50-75 articles per minute, although this number is notlimiting. Moreover, the increased speed of the articles from the fillergaps can reduce gaps between the articles on the main belt 312 relativeto conveyances without filler sheets 372, 374, 376, 378. Moreover,removal of the filler sheets 372, 374, 376, 378 provides the option ofslowing the article processing rate.

In some embodiments, the filler sheets 372, 374, 376, 378 include anoise-reducing element, such as a noise-reducing coating. Thenoise-reducing element can be located between an upper portion of thefiller sheet 372 and the main belt 312 (e.g., the movable components116). The coating can be a bonded friction coating, resin, polymer,fluoropolymer (e.g., polytetrafluoroethylene), graphite, molybdenumdisulfide, rubber, latex, or another material.

With reference to FIG. 7, the filler sheets 372, 374, 376, 378 can bemounted with the frame 330. The filler sheet 372 can be mounted acrossthe tracks 331, 332. The filler sheet 372 can include one or more legs373 having thereon mounts for attachment with the tracks 331, 332. Thelegs 373 can raise the level of the filler sheet 372 into contact withthe main belt 312. The legs 373 can be movably mounted with the channels334 of the tracks 331, 332. The attachment with the legs 373 can be byone or more bolts. Heads of the bolts can be alternately slidablymounted or tightened with respect to the channels 334. By engagementwith the tracks 331, 332, the filler sheets 372, 374, 376, 378 can bereconfigurable to meet system requirements.

Control System of a Modular Transfer Unit

FIGS. 8 and 9 depict the modular transfer unit 300, as described above.The modular transfer unit 300 can further include a control system 800.The control system 800 can include a user interface 810, a programmablecontroller 820, the programmable controller 820 having a processor 830and a computer readable medium 840, one or more encoders 850, one ormore divert system control modules 812, 814, 816, the one or morearticle sensors (diverter sensors 862, 864, 866), and/or the one or morearticle sensors (chute sensors 363, 365, 367).

The user interface 810 can enable setup and configuration of the modulartransfer unit 300. The interface 810 can allow a technical or mechanicalinstaller to get the unit 300 setup and ready to be run in a shortamount of time. The interface 810 can contain a full suite of setupconfigurations and/or documentation to assist user in setting up theunit 300. The interface 810 can include a user interface for displayingand one or more user input devices for inputting information for use bythe controller 820. The user interface can be a screen. The user inputdevice can be a mouse, keyboard, touchscreen or other user input system.

The interface 810 can facilitate automated and nearly automated setup.The interface 810 can be configured to prompt the user to input thedesired parameters for the sorter. The prompt can include: the length ofthe modular transfer unit 300 (e.g., between the rollers 314, 314 a);the width of the modular transfer unit 300; the number of divert system;the number of belts per divert system; a distance (D1, D2, D3) to eachof the divert system or to the sensors 362-366; a desired linear speedof the main belt; a location of any filler sheets or gaps; and/or thedesired angle of divert into the chutes; or the desired speed of thedivert system belts.

The controller 820 can include operation instructions stored on themedium 840 and executable by the processor 830. When executed, theoperation instructions can cause the controller 820 to operate themodular transfer system 300.

The one or more encoders 850 can be used to measure a speed of the mainbelt 312. This information can be used in the operation of the unit 300by the controller 820. The speed of the main belt 312 can be used totime operation of the diverter systems to divert an article off a sideof the main belt 312. In some embodiments, the encoders 850 can be pulsegenerators. A pulse generator with a trigger wheel (e.g., similar to theflywheel of a car) can be used to measure the main belt 312 speed. Thisapproach can supply adequate resolution for package tracking. Someembodiments of the unit 300 can use a “time of flight” speed trackingmodel, though the actual tracking may be based on pulses and not a timerin the controller 820. Since article tracking is not alwayszone-to-zone, knowing the speed of the main belt 312 can be helpful forthe controller 820. The one or more encoders and/or pulse generators850, run delay timers and/or speed reference settings can be used todetermine the main belt 312 speed.

The one or more divert system control modules 812, 814, 816 can be usedto control the diverter systems. The divert system control modules 812,814, 816 can be the motor driver cards used to store the settings forthe motors of the unit 300. This allows for the motors to remain closeto the cards being utilized and to simplify power distribution to thecards. In most cases, the divert system control modules 812, 814, 816will contain settings for the motors and/or the motion controlling logicto power the diverter systems.

The one or more article sensors (or diverter sensors or chute sensors)can be used to send a signal to the controller 820 to locate an article.The diverter sensors can indicate the presence or approach of an articleto the diverter system. The controller 820 can then selectively operatethe diverter system. The chute sensors can confirm that the article hasbeen diverted.

The controller 820 can communication with a controller of a mainconveyor system with which the unit 300 is interface. The controller 820can communicate with a barcode scanner or OCR system on the unit 300 toidentify articles thereon. The controller 820 can communicate with thedivert system control modules. The controller 820 can communicate withthe encoder 850. The controller 820 can track packages along the sorter(e.g., to time the diverter belts). The controller 820 can collect datafor the unit 300 such as, but not limited to: the number of diverts ofarticles; the number of missed diverts; the number of misread, or otherevents. The controller 820 can interface with the interface 810, such asto receive data about the unit 300 for use in the operation instructionsexecution. In some variants, the controller 820 can initiate safety andstop interlocking, such as by way of a safety relay.

In some embodiments, the controller 820 can receive a signal from theone or more article sensors that an article on the main belt 312 is at adivert zone. The controller 820 can determine that the article is to bediverted to one side or other of the main belt 312. In response to thisdetermination, the controller 820 can initiate the diverter system todivert the article towards the side of the main belt and into one of thechutes. The controller 820 can determine the run delay timing on thediverter system belts. In some embodiments, the one or more chutesensors are used to confirm packages that have made it off the main belt312. In some embodiments, the unit 300 is not configured to stop oraccumulate packages thereon. The one or more diverter sensors, and oneor more chute sensors can tie back into the divert system controlmodules 812, 814, 816 and/or the controller 820.

FIG. 9 depicts the unit 300 with the added complexity of not knowingthere was a building column in the way of the chute 342. In this case,the chute 342 and the divert belt 322 have been backed up earlier on theunit 300 (moved to the right in the figure), thereby providing space forthe building column. The control system 800 can adjust operation of themodular transfer unit accordingly. In one implementations, the userinterface 810 can prompt a user to input the new location of the divertbelt 322 relative to a datum. For example, the user can re-enterdistance D1 as distance D1′. In another implementation, the track systemcan include one or more sensors that can detect and/or measure theposition of the divert belt 322. The controller 820 can receive thisdata and adjust operation of the modular transfer unit accordingly. Insome embodiments, the control system 800 can detect that the position ofthe diverter zone has changed, such as with position sensors. In certainembodiments, the control system 800 can adjust operation of the divertbelt 322 to adapt for the changed position of the diverter zone. Forexample, the timing and/or speed at which the divert belt 322 isoperated can be modified in response to and/or to adapt for the changein position of the diverter zone.

Another Example of a Modular Transfer Unit

FIG. 10 depicts a modular transfer unit 1000, similar to the previouslydescribed modular transfer units 100, 300. The unit 1000 can includedual-stage diverter belt technology 1020. At the chute stations 1042,1043, a diverter system with two belts can be used.

The unit 1000 can include one or more diverter systems 1022. Thediverter systems 1022 can be aligned to travel in the direction of theprimary flow of the main belt (not shown) from the infeed side 1002 to apass-through side 1004. The diverter systems 1022 can be attached withtracks 1031, 1033, similar to the above described tracks 331, 332. Thetrack system can accommodate reconfiguration of the unit 1000. Dependingon usage and the angle of the belt relative to the primary flowdirection, the diverter systems 1022 can be used for high speed skew,in-line gapping, merge and diverge tables, and/or pick and pass modules.

FIG. 10 depicts unit 1000 with three inline diverter systems. Certainembodiments have different numbers of inline diverter systems, such asone, two, four, five, six, or more. In some embodiments, the unit 1000itself can be used to gap and separate products eliminating the need fora brake metering belt induction to the sorter.

Certain Other Embodiments

While certain embodiments have been described, these embodiments havebeen presented by way of example only and are not intended to limit thescope of the disclosure. Indeed, the novel methods and systems describedherein may be embodied in a variety of other forms. Furthermore, variousomissions, substitutions and changes in the systems and methodsdescribed herein may be made without departing from the spirit of thedisclosure. The accompanying claims and their equivalents are intendedto cover such forms or modifications as would fall within the scope ofthe disclosure. Accordingly, the scope of the present disclosure isdefined only by reference to the claims presented herein or as presentedin the future.

Features, materials, characteristics, or groups described in conjunctionwith a particular aspect, embodiment, or example are to be understood tobe applicable to any other aspect, embodiment or example described inthis section or elsewhere in this specification unless incompatibletherewith. All of the features disclosed in this specification(including any accompanying claims, abstract and drawings), and/or allof the steps of any method or process so disclosed, may be combined inany combination, except combinations where at least some of suchfeatures and/or steps are mutually exclusive. The protection is notrestricted to the details of any foregoing embodiments. The protectionextends to any novel one, or any novel combination, of the featuresdisclosed in this specification (including any accompanying claims,abstract and drawings), or to any novel one, or any novel combination,of the steps of any method or process so disclosed.

Furthermore, certain features that are described in this disclosure inthe context of separate implementations can also be implemented incombination in a single implementation. Conversely, various featuresthat are described in the context of a single implementation can also beimplemented in multiple implementations separately or in any suitablesubcombination. Moreover, although features may be described above asacting in certain combinations, one or more features from a claimedcombination can, in some cases, be excised from the combination, and thecombination may be claimed as a subcombination or variation of asubcombination.

For purposes of this disclosure, certain aspects, advantages, and novelfeatures are described herein. Not necessarily all such advantages maybe achieved in accordance with any particular embodiment. Thus, forexample, those skilled in the art will recognize that the disclosure maybe embodied or carried out in a manner that achieves one advantage or agroup of advantages as taught herein without necessarily achieving otheradvantages as may be taught or suggested herein.

Certain Terminology

Certain terminology may be used in the following description for thepurpose of reference only, and thus is not intended to be limiting. Forexample, terms such as “upper”, “lower”, “upward”, “downward”, “above”,“below”, “top”, “bottom”, “left”, and similar terms refer to directionsin the drawings to which reference is made. Such terminology may includethe words specifically mentioned above, derivatives thereof, and wordsof similar import. Similarly, the terms “first”, “second”, and othersuch numerical terms referring to structures neither imply a sequence ororder unless clearly indicated by the context.

Conditional language, such as “can,” “could,” “might,” or “may,” unlessspecifically stated otherwise, or otherwise understood within thecontext as used, is generally intended to convey that certainembodiments include, while other embodiments do not include, certainfeatures, elements, and/or steps. Thus, such conditional language is notgenerally intended to imply that features, elements, and/or steps are inany way required for one or more embodiments or that one or moreembodiments necessarily include logic for deciding, with or without userinput or prompting, whether these features, elements, and/or steps areincluded or are to be performed in any particular embodiment.

Conjunctive language such as the phrase “at least one of X, Y, and Z,”unless specifically stated otherwise, is otherwise understood with thecontext as used in general to convey that an item, term, etc. may beeither X, Y, or Z. Thus, such conjunctive language is not generallyintended to imply that certain embodiments require the presence of atleast one of X, at least one of Y, and at least one of Z.

Terms relating to circular shapes as used herein, such as diameter orradius, should be understood not to require perfect circular structures,but rather should be applied to any suitable structure with across-sectional region that can be measured from side-to-side. Termsrelating to shapes generally, such as “spherical” or “circular” or“cylindrical” or “semi-circular” or “semi-cylindrical” or any related orsimilar terms, are not required to conform strictly to the mathematicaldefinitions of spheres, circles, cylinders or other structures, but canencompass structures that are reasonably close approximations.

The terms “approximately,” “about,” and “substantially” as used hereinrepresent an amount close to the stated amount that still performs adesired function or achieves a desired result. For example, in someembodiments, as the context may permit, the terms “approximately”,“about”, and “substantially” may refer to an amount that is within lessthan or equal to 10% of the stated amount. The term “generally” as usedherein represents a value, amount, or characteristic that predominantlyincludes or tends toward a particular value, amount, or characteristic.As an example, in certain embodiments, as the context may permit, theterm “generally parallel” can refer to something that departs fromexactly parallel by less than or equal to 20 degrees. As anotherexample, in certain embodiments, as the context may permit, the term“generally perpendicular” can refer to something that departs fromexactly perpendicular by less than or equal to 20 degrees.

The terms “comprising,” “including,” “having,” and the like aresynonymous and are used inclusively, in an open-ended fashion, and donot exclude additional elements, features, acts, operations, and soforth. Likewise, the terms “some,” “certain,” and the like aresynonymous and are used in an open-ended fashion. Also, the term “or” isused in its inclusive sense (and not in its exclusive sense) so thatwhen used, for example, to connect a list of elements, the term “or”means one, some, or all of the elements in the list.

Overall, the language of the claims is to be interpreted broadly basedon the language employed in the claims. The language of the claims isnot to be limited to the non-exclusive embodiments and examples that areillustrated and described in this disclosure, or that are discussedduring the prosecution of the application.

Summary

Although the modular conveyor system has been disclosed in the contextof certain embodiments and examples, it will be understood by thoseskilled in the art that this disclosure extends beyond the specificallydisclosed embodiments to other alternative embodiments and/or uses ofthe embodiments and certain modifications and equivalents thereof. Thescope of the present disclosure is not intended to be limited by thespecific disclosures of preferred embodiments in this section orelsewhere in this specification, and may be defined by claims aspresented in this section or elsewhere in this specification or aspresented in the future. The language of the claims is to be interpretedbroadly based on the language employed in the claims and not limited tothe examples described in the present specification or during theprosecution of the application, which examples are to be construed asnon-exclusive.

The following is claimed:
 1. A modular conveyor system comprising: aframe having a first end and a second end; a main belt supported by theframe, the main belt comprising a plurality of hingedly-connected beltmodules, each of the plurality of belt modules comprising a body and aplurality of spherical balls, the spherical balls having an upperportion that protrudes above an upper surface of the body and a lowerportion that protrudes below a lower surface of the body, the sphericalballs configured to rotate relative to the body; a main belt drive unitconfigured to drive the main belt in a first direction, the main beltdrive unit comprising a motor and a drive roller, the drive rollerengaged with the main belt at the first end of the frame; and a diverterbelt supported by the frame, the diverter belt configured to travel in asecond direction that is generally perpendicular to the first direction,the diverter belt positioned at least partially underneath the main beltsuch that the diverter belt contacts the protruding lower portion of thespherical balls and the relative movement of the main and diverter beltscauses the spherical balls to rotate; wherein the diverter belt isconfigured to be repositioned between the first end and a second end ofthe frame along a track system while remaining supported by the frame.2. The modular conveyor system of claim 1, wherein the track systemcomprises a first and second track, the diverter belt mounted with achannel on each of the first and second tracks by one or more bracketsmounted within the channels, the channels extending in the firstdirection.
 3. The modular conveyor system of claim 2, wherein thechannels are generally T-shaped, and the brackets are coupled within thefirst and second tracks by one or more bolts, each of the bolts having ahead slidingly engaged within one of the channels.
 4. The modularconveyor system of claim 1, wherein the frame comprises first and secondsupport rails, the first and second support rails coupled together byone or more struts, the first and second tracks coupled with the firstand second support rails, respectively.
 5. The modular conveyor systemof claim 3, wherein the diverter belt is slidable relative to the firstand second tracks by loosening the one or more bolts and fixed relativeto the first and second tracks by tightening the one or more bolts. 6.The modular conveyor system of claim 1, wherein the diverter beltcomprises multiple diverter belts in a single module.
 7. The modularconveyor system of claim 1, further comprising a filler sheet coatedwith a sound dampening material, the filler sheet filling a gap adjacentto one of the diverter belt and the drive roller, the filler sheetengaged with the lower portion of the spherical ball.
 8. A modularconveyor system comprising: a frame having a first end and a second end;a main belt comprising a plurality of hingedly-connected belt modules,each of the plurality of belt modules comprising a body and a pluralityof spherical balls, the spherical balls having an upper portion thatprotrudes above an upper surface of the body and a lower portion thatprotrudes below a lower surface of the body, the spherical ballsconfigured to rotate relative to the body; a main belt drive unitconfigured to drive the main belt in a first direction at a main beltspeed, the main belt drive unit comprising a motor and a drive roller,the drive roller engaged with the main belt at the first end of theframe; and a filler sheet positioned at least partially underneath themain belt such that the filler sheet contacts the protruding lowerportion of the spherical balls and the relative movement of the mainbelt and filler sheet causes the spherical balls to rotate; wherein thefiller sheet is repositionable between the first end and the second endof the frame along a track system; and wherein an article conveyed overthe filler sheet by the main belt in the first direction is in contactwith the upper portion of the spherical balls and is conveyed in thefirst direction at a conveyance speed, the conveyance speed being abouttwice the main belt speed.
 9. The modular conveyor system of claim 8,wherein the filler sheet comprises a sound dampening material engagedwith the protruding lower portion of the spherical balls.
 10. Themodular conveyor system of claim 8, wherein the track system comprises afirst track and second track, the filler sheet mounted with a channel oneach of the first and second tracks, the channels extending in the firstdirection.
 11. The modular conveyor system of claim 8, furthercomprising a diverter belt configured to travel in a second directionthat is generally perpendicular to the first direction, the firstdiverter belt positioned at least partially underneath the main beltsuch that the diverter belt contacts the protruding lower portion of thespherical balls and the relative movement of the main and diverter beltcauses the spherical balls to rotate, the diverter belt beingrepositionable between the first end and the second end of the framealong the track system.
 12. The modular conveyor system of claim 11,wherein the filler sheet is positioned adjacent to the diverter beltsuch that the conveyance speed is maintained across the diverter beltand the filler sheet.
 13. The modular conveyor system of claim 12,wherein the conveyance speed is maintained from the first end of theframe to the second end of the frame by one or more adjacent diverterbelts and adjacent fillers sheets.
 14. A modular conveyor systemcomprising: a frame having a first end and a second end; a main beltcomprising a plurality of hingedly-connected belt modules, each of theplurality of belt modules comprising a body and a plurality of sphericalballs, the spherical balls having an upper portion that protrudes abovean upper surface of the body and a lower portion that protrudes below alower surface of the body, the spherical balls configured to rotaterelative to the body; a main belt drive unit configured to drive themain belt in a first direction, the main belt drive unit comprising amotor and a drive roller, the drive roller engaged with the main belt atthe first end of the frame; a diverter belt configured to travel in asecond direction that is generally perpendicular to the first direction,the diverter belt positioned at least partially underneath the main beltsuch that the diverter belt contacts the protruding lower portion of thespherical balls and the relative movement of the main and diverter beltscauses the spherical balls to rotate; a user interface and an inputmodule; wherein the diverter belt is repositionable along a track systemextending between the first end and a second end of the main belt; acontrol system comprising a processor and a computer-readable mediumhaving operation instructions thereon, the operation instructions, whenexecuted by the processor configured to: receive a position of adiverter zone; detect that an article on the main belt moving in thefirst direction is at the divert zone; determine that the article is tobe diverted towards a side of the main belt; and operate the diverterbelt to cause the article to change from moving primarily in the firstdirection to moving primarily in the second direction and towards theside of the main belt.
 15. The modular transfer system of claim 14,wherein the control system is further configured to determine whether anarticle is at the divert zone based on a signal received from a sensor.16. The modular transfer system of claim 14, wherein the control systemis further configured to determine whether an article is at the divertzone based on a time delay after receiving the signal from the sensor,the sensor being positioned at a location before the divert zone in theprimary direction of travel.
 17. The modular transfer system of claim14, wherein the control system is further configured to prompt a userthrough the user interface to input the position of the diverter zonerelative to a datum.
 18. The modular transfer system of claim 14,wherein the control system is further configured to automatically detectthe position of the diverter zone based on a position of the divert beltalong the track system.
 19. The modular transfer system of claim 14,wherein the control system is further configured to: detect that theposition of the diverter zone has changed; and adjust operation of thediverter belt to adapt for the changed position.